Method for manufacturing socks

Abstract

To provide a sock that can increase the supporting force thereof and effectively maintain the arch function of the sole while enhancing the productivity.SOLUTION: Socks 10L and 10R are formed by a circular sock knitting machine, including opening parts 20, main bodies 30 and toe parts 40. Heel parts formed by core lines are not included, and the opening parts 20 and the main bodies 30 are all formed by a circular sock knitting machine using rubber yarn. The main bodies 30 have supporting parts 35 that extend belt-like, and the supporting parts 35 are formed by semi-circle arc-shaped parts 35e and two approximately straight line parts 35c and 35d that extend from both ends of the semi-circle arc-shaped parts 35e and cross each other. The stretching rate of the supporting parts 35 is lower than the stretching rate of the main bodies 30 other than the supporting parts.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to tubular socks. Manufacturing method

Background Art

[0002] On the sole of a human foot, there is an arch-shaped depression formed by connecting three points: the base of the big toe, the base of the little toe, and the heel. This arch is formed by two longitudinal arches from the big toe side and the little toe side to the heel respectively, and one transverse arch connecting the big toe to the little toe horizontally. The inner longitudinal arch constitutes the so-called "arch of the foot".

[0003] The depression due to the arch on the sole has functions of a cushion to relieve the impact at the time of landing, a spring function to kick the ground, and a function to maintain balance when standing. When the depression on the sole is firmly formed, it also leads to enhancing the motor ability and supporting the body with the correct center of gravity.

[0004] However, when a human walks or runs for a long time, the function of the arch on the sole may decline. Therefore, socks that maintain the function of the arch by wearing them are disclosed in, for example, Patent Document 1

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] According to the socks of Patent Document 1, by forming an X-shaped support part on the sole using a high-elastic material having a knitting structure and a material that increase the elastic modulus of the constituent parts, it is said that the function of the arch on the sole of the user wearing the socks can be maintained by utilizing the tensile force.

[0007] ​ However, in the sock of Patent Document 1, since the support part extending from the sole is interrupted at the heel part, the pulling force by the support part is not sufficient. The reason why the support part is interrupted at the heel part is that in the manufacturing process of the sock of Patent Document 1, the heel part is formed in the same manner as a general sock.

[0008] When knitting a sock with a heel using a circular sock knitting machine, the cylinder rotates during knitting in the body part. However, when the knitting transitions from the body part to the heel part, the cylinder is once changed from a rotational movement to a forward and reverse reciprocating rotational movement, and the knitting of the heel part is carried out as it is. Further, when the knitting transitions from the heel part to the foot part, the cylinder returns to a rotational movement again to carry out the knitting of the foot part. For this reason, it is difficult to form a continuous support part from the sole to the upper rear of the heel.

[0009] In addition, according to the sock of Patent Document 1, since the support part extending from the sole is interrupted at the heel part, the hold of the heel part is not sufficient, and there is also a concern about the problem that it is easy to come off when the user performs intense exercise.

[0010] The present invention aims to provide a sock that can enhance the support force and effectively maintain the function of the arch of the sole while improving productivity. Manufacturing method for this purpose.

Means for Solving the Problems

[0011] The manufacturing method of the sock of the present invention is a method for manufacturing a tubular sock having a top edge part, a main body part, and a toe part, which is knitted by a circular sock knitting machine. In the top edge part and the main body part, rubber threads are inserted into all courses. The main body portion has a support portion extending in a strip shape, and the support portion is composed of a semi-circular arc portion and two straight portions extending from both ends of the semi-circular arc portion and crossing each other. The two straight portions cross at a position corresponding to the instep when the sock is worn on the foot. The semi-circular arc portion surrounds the upper rear of the heel when the sock is worn on the foot and connects to each of the straight portions. When the sock is worn on the foot, the heel enters the portion surrounded by the semi-circular arc portion and the two straight portions extending from both ends of the semi-circular arc portion and crossing each other. One of the straight portions of the support portion is short, and when the sock is worn on the foot, its free end is located near the base of the fourth toe on the sole side. The other straight portion is long, and when the sock is worn on the foot, its free end reaches the side of the base of the thumb. The expansion and contraction rate of the support portion is lower than that of the main body portion other than the support portion. The opening part and the main body part are Knitting while rotating the cylinder of the circular knitting machine for socks in one direction to do It is characterized by the above.

Effect of the Invention

[0012] According to the present invention, it is possible to provide socks that can enhance the support force and effectively maintain the function of the arch on the sole of the foot while improving productivity. Manufacturing method It can be provided.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, with reference to the drawings, the sock according to the embodiment of the present invention will be described. FIG. 1 is a plan view of the socks 10L and 10R of the present embodiment as seen from the upper side, and FIG. 2 is a plan view of the socks 10L and 10R of the present embodiment as seen from the sole side. FIG. 3 is a side view of the sock 10R as seen from the inside, and FIG. 4 is a side view of the sock 10R as seen from the outside. In this specification, the socks 10L and 10R are tubular socks. In the present invention, the "tubular sock" refers to a sock having no heel part with a gore line formed by a half-rotation reciprocating motion of a cylinder of a circular knitting sock knitting machine. The sock 10L is for the left foot, and the sock 10R is for the right foot, and they have a bilaterally symmetric structure according to the foot to be worn. Otherwise, since both have a common configuration, hereinafter, only the sock 10R will be described, and the overlapping description of the sock 10L will be omitted.

[0015] As shown in FIGS. 1 to 4, the sock 10R is formed by connecting a top edge portion 20, a main body portion 30, and a toe portion 40 in series. The main body portion 30 has a first cylindrical portion 31 adjacent to the top edge portion 20, a second cylindrical portion 32 adjacent to the first cylindrical portion 31, a third cylindrical portion 33 adjacent to the second cylindrical portion 32, and a fourth cylindrical portion 34 adjacent to the third cylindrical portion 33 and the toe portion 40. As shown in FIG. 2, a support portion 35 and a reinforcing portion 36 are formed in the second cylindrical portion 32, the third cylindrical portion 33, and the fourth cylindrical portion 34. In FIG. 2, when the sock 10R is worn on the right foot, the side of the big toe (inside) of the foot is defined as IS, and the side of the little toe (outside) is defined as OS.

[0016] The support portion 35 has a substantially equal-width strip shape and is provided over the second cylindrical portion 32, the third cylindrical portion 33, and the fourth cylindrical portion 34. The strip-shaped support portion has a lower expansion and contraction rate than the expansion and contraction rates of the cylindrical portions 32, 33, and 34 of the main body portion other than that, and is composed of a semi-circular arc portion 35e and two substantially straight portions 35c and 35d that extend from both ends of the semi-circular arc portion and cross each other. A portion 37 surrounded by the semi-circular arc portion 35e and the two substantially straight portions 35c and 35d that extend from both ends of the semi-circular arc portion and cross each other becomes the location where the heel is positioned when wearing socks. It is preferable to provide a reinforcing portion 36 in this surrounded portion 37. The reinforcing portion 36 is octagonal or circular and is disposed near the center of the second cylindrical portion 32. The shape of the reinforcing portion 36 is not limited. As shown in FIGS. 5 to 7 described later, when the sock 10R is worn on the foot, the reinforcing portion 36 is positioned under the calcaneus of the foot, and has a function of reinforcing the knitted fabric, a function of swelling the heel portion, and a function as a guide for the position of the heel when wearing the sock 10R.

[0017] The support portion 35 will be described in detail with reference to the drawings. When the sock 10R is worn on the right foot, one end portion (free end) 35a is disposed near the base of the ring finger on the sole side. The support portion 35 extends linearly or in a smooth curve from the one end portion 35a toward between the reinforcing portion 36 and the thumb side IS, and further extends so as to surround the reinforcing portion 36 in a semi-circular arc shape to reach the vicinity of the little finger side OS, and extends linearly or in a smooth curve from here toward the thumb side IS and terminates at the side surface of the base of the thumb, forming the other end portion (free end) 35b (see FIGS. 1 and 3). Thereby, the periphery of the reinforcing portion 36 is surrounded by the support portion 35.

[0018] As described later, the main body portion 30 of the sock 10R is knitted by a circular sock knitting machine (single cylinder knitting machine). However, even when knitting is performed only by a circular sock knitting machine, the support portion 35 can be made to have low stretchability by cut bosses and the vicinity of the reinforcing portion 36 can be projected to some extent by the cut bosses of the reinforcing portion 36 (see FIGS. 3 and 4). Therefore, it is convenient when forming the heel by molding using a foot model after knitting the sock 10R.

[0019] As shown in FIG. 2, in the support portion 35, the portion extending from one end portion 35a to the vicinity of the reinforcing portion 36 is defined as the first band portion 35c, the portion extending from the other end portion 35b to the vicinity of the reinforcing portion 36 is defined as the second band portion 35d, and the semi-circular arc-shaped portion connecting the first band portion 35c and the second band portion 35d is defined as the intermediate band portion (also referred to as the semi-circular arc-shaped portion) 35e. The first band portion 35c and the second band portion 35d each constitute a substantially linear portion, and the intermediate band portion 35e constitutes a semi-circular arc-shaped portion. When the sock 10R is worn on the right foot, the first band portion 35c and the second band portion 35d cross at a position corresponding to the instep of the right foot. At this time, the intermediate band portion 35e surrounds the upper rear part of the right heel and is connected to the first band portion 35c and the second band portion 35d.

[0020] When the crossing center point of the first band portion 35c and the second band portion 35d is defined as CP, when the crossing angle of the first band portion 35c with respect to the straight line LN parallel to the axis of the sock 10R passing through the crossing center point CP is defined as θ1, and the crossing angle of the second band portion 35d with respect to the straight line LN is defined as θ2, θ1 < θ2.

[0021] Next, a method for manufacturing the sock 10R will be described. The method for manufacturing the sock 10L is the same. The sock 10R is knitted by a double-knit method using a surface yarn and a back yarn using a circular sock knitting machine (hereinafter referred to as a sock knitting machine). In this embodiment, except for the upper side of the second cylindrical portion 32, it is knitted by flat knitting.

[0022] The material of the surface yarn is not particularly limited, and wooly nylon, base yarn (cotton, cotton-polyester blended yarn, etc.) can be used.

[0023] The back yarn uses an FTY yarn (a yarn obtained by winding a wooly nylon yarn or the like around an elastic yarn) or a wooly nylon yarn or the like. The thickness of the back yarn is not particularly limited.

[0024] Furthermore, rubber threads are used for all courses as the inserted threads to which additional pressure is applied. As the rubber threads, DCY rubber threads obtained by double covering natural rubber or polyurethane rubber as the core thread with polyester or nylon are used. In the present embodiment, DCY rubber threads are used from the opening part 20 to the body part 30. The rubber threads are not formed and knitted by forming stitch loops, but are inserted for each course, and the insertion mode is not changed depending on the part.

[0025] First, while rotating the cylinder of the sock knitting machine in one direction, the opening part 20 is knitted. The opening part 20 may be a single top or a double welt.

[0026] Next, while rotating the cylinder of the sock knitting machine in one direction, the first cylindrical part 31 is knitted. The stitch density and the amount of rubber thread insertion are set so that both the sole side and the top side of the first cylindrical part 31 have medium pressure (P1) as the degree of compression when worn on the foot.

[0027] Thereafter, while rotating the cylinder of the sock knitting machine in one direction, the second cylindrical part 32 is knitted. The stitch density and the amount of rubber thread insertion are set so that both the sole side and the top side of the second cylindrical part 32 have a weak pressure P2 (<P1) lower than the medium pressure. This is for facilitating the formation of the heel part protruding in a later process.

[0028] Since the sole side of the second cylindrical part 32 includes the intermediate belt part 35e of the support part 35, the opening side parts of the first belt part 35c and the second belt part 35d, and the reinforcing part 36, these are also formed simultaneously during the knitting of the second cylindrical part 32. The intermediate belt part 35e, the opening side parts of the first belt part 35c and the second belt part 35d, and the reinforcing part 36 are formed by the cut boss method. The cut boss method is a knitting method in which, in the process of knitting the knitted fabric, a thread for cut boss (in the present invention, a thread with little stretchability, such as cotton or a cotton / polyester blended yarn) is fed as an added thread at the start position of the cut boss and knitting in the course direction is started, and at the end position on the same course, the added thread is removed and the thread is immediately cut.

[0029] As the material of the attaching yarn that forms the top edge side portions of the middle band portion 35e, the first band portion 35c, and the second band portion 35d, it is preferable that the material has lower stretchability than rubber yarn. Thereby, the tensile resistance of the top edge side portions of the middle band portion 35e, the first band portion 35c, and the second band portion 35d can be enhanced. On the other hand, as the material of the attaching yarn that forms the reinforcing portion 36, although not particularly limited, it is preferable that the material is a non-slip material.

[0030] On the top side of the second cylindrical portion 32, it is knitted by a spiral mesh knitting method that is less likely to slacken and is easy to stretch. Thereby, the fitting feeling can be enhanced. The spiral mesh knitting is a knitting method in which in a two-yarn knitting, one yarn floats without forming loops at every other needle and every other course or several courses. Since the spiral mesh knitting is described in, for example, Utility Model Registration No. 3219235, the description thereof is omitted. However, the top side of the second cylindrical portion 32 may be knitted by flat knitting.

[0031] Thereafter, while rotating the cylinder of the sock knitting machine in one direction, the third cylindrical portion 33 is knitted. The top side of the third cylindrical portion 33 is set with the stitch density and the rubber yarn insertion amount so as to have a medium pressure P3 (≒P1). On the other hand, the sole side of the third cylindrical portion 33 is set with the stitch density and the rubber yarn insertion amount so as to have a strong pressure P4 (>P3).

[0032] Since the third cylindrical portion 33 includes the middle portions (between the cross center point CP and the reinforcing portion 36) of the first band portion 35c and the second band portion 35d of the support portion 35, these will also be formed simultaneously during the knitting of the third cylindrical portion 33. The middle portions of the first band portion 35c and the second band portion 35d are also formed by the cut boss method using attaching yarn with low stretchability similar to the middle band portion 35e and the like. By such knitting, the sock 10R will not have a heel portion formed by a gore line.

[0033] After that, while rotating the cylinder of the sock knitting machine, the fourth cylindrical part 34 is knitted. The degree of stitch density and the amount of rubber thread insertion are set so that the pressure P5 (>P4), which is an ultra-strong pressure with a stronger compression degree than the sole side of the third cylindrical part 33, is applied to both the sole side and the instep side on the fourth cylindrical part 34 side. Furthermore, in order to achieve this ultra-strong pressure, it is more preferable to use a cut boss method to form a fabric that is difficult to stretch with additional yarn. In this case, the cut boss yarn is preferably a stretchable wooly nylon yarn or the like. According to this embodiment, since the pressure increases in the order of the second cylindrical part 32, the third cylindrical part 33, and the fourth cylindrical part 34 from the intermediate band part 35e to the toe of the sock 10R, the sense of support when wearing the sock can be increased.

[0034] Since the fourth cylindrical part 34 includes the toe side parts (between the cross center point CP and the toe part 40) of the first band part 35c and the second band part 35d of the support part 35, these parts will also be formed simultaneously during the knitting of the fourth cylindrical part 34. The toe side parts of the first band part 35c and the second band part 35d are also formed by the cut boss method using a low-stretch additional yarn similar to the intermediate band part 35e and the like. As is clear from the above, the stretch ratio of the support part 35 is lower than that of the main body part 30 other than the support part 35, that is, it is difficult to stretch.

[0035] After that, the sock knitting machine knits the toe part 40. Specifically, while the cylinder of the sock knitting machine reciprocates between forward rotation and reverse rotation, the knitting needles acting on the stitch formation are sequentially reduced to knit the trapezoidal claw tip part on the sole side by the reduced stitches, and then, contrary to the formation of the reduced stitches, increased stitches are made to knit the trapezoidal claw tip part on the instep side. After knitting, the opening is closed by using appropriate means such as linking to form the toe part 40.

[0036] With the above, the knitting process of the sock 10R is completed. Although the sock 10R is knitted with the vicinity of the reinforcing part 36 bulging, it is desirable to ensure the protruding amount as the heel part. Therefore, in order to approximate the shape of the foot, it is fitted into a foot mold (not shown) so that the vicinity of the reinforcing part 36 protrudes more, steam is applied for shaping, and it is dried to form the heel part. As a result, although it receives a force such that the vicinity of the reinforcing part 36 expands, it is possible to suppress the knitted fabric from becoming too thin due to the supplementary yarn of the reinforcing part 36. With the above, the manufacturing process of the sock 10R is completed.

[0037] According to the present embodiment, since the top edge part 20 and the main body part 30 of the sock 10R can be continuously knitted by a sock knitting machine, the manufacturing cost can be suppressed and the productivity can be increased.

[0038] FIG. 5 is a view of the sole of the sock 10R worn on the right foot. FIG. 6 is a view of the sock 10R worn on the right foot as seen from the inside. FIG. 7 is a view of the sock 10R worn on the right foot as seen from the outside. As shown in the figures, the reinforcing part 36 is located at the heel of the right foot.

[0039] According to the present embodiment, since the support part 35 is formed using a supplementary yarn having lower stretchability than the ground yarn, when the sock 10R is worn on the foot, as shown in FIG. 5, tensile stress is generated in the first band part 35c along its longitudinal direction (arrow A direction), and in the second band part 35d crossing the first band part 35c, tensile stress is generated along its longitudinal direction (arrow B direction). The tensile forces in the A direction and the B direction act so as to resist the deterioration of the functions of the inner longitudinal arch structure and the outer longitudinal arch structure of the foot.

[0040] At this time, referring to FIG. 1, since the crossing angle θ1 of the first band part 35c with respect to the straight line LN is smaller than the crossing angle θ2 of the second band part 35d, a force for lifting the instep of the foot can be effectively generated corresponding to the asymmetric shape of the instep of the right foot.

[0041] Furthermore, as shown in FIGS. 6 and 7, the first band portion 35c and the second band portion 35d are continuous with an intermediate band portion 35e that wraps around to the upper rear of the heel portion. Therefore, tensile forces in the A direction and the B direction can be effectively generated with the upper rear of the heel portion as a base point, and a force for pulling up the arch of the foot can be generated more effectively. In addition, since the intermediate band portion 35e is always subjected to a tensile force during wearing, even if a user wearing the sock 10R engages in intense exercise, it is possible to prevent the sock 10R from coming off.

[0042] The color of the supplementary yarn used for forming the support portion 35 is not limited. However, if the color of the supplementary yarn is the same as the color of the ground yarn, the overall sock will be of a single color and the support portion 35 will not stand out, so it can be suitably used for business purposes. On the other hand, if the color of the supplementary yarn is different from the color of the ground yarn, the support portion will be emphasized and it can be suitably used for sports purposes. Also, the length of the sock is arbitrary and not restricted.

Explanation of Reference Numerals

[0043] 10L, 10R Socks 20 Wearing opening 30 Main body portion 31 First cylindrical portion 32 Second cylindrical portion 33 Third cylindrical portion 34 Fourth cylindrical portion 35 Support portion 36 Reinforcement portion

Claims

1. In a method for manufacturing a tubular sock having an opening edge portion, a body portion, and a toe portion, which is knitted by a circular sock knitting machine, the rubber thread is inserted into all the courses of the opening edge portion and the body portion, the body portion has a support portion extending in a band shape, and the support portion is composed of a semi-circular arc portion and two straight portions extending from both ends of the semi-circular arc portion and crossing each other. The two straight portions cross at a position corresponding to the instep when the sock is worn on the foot. The semi-circular arc portion surrounds the upper rear part of the heel when the sock is worn on the foot and is connected to each of the straight portions. When the sock is worn on the foot, the heel enters the portion surrounded by the semi-circular arc portion and the two straight portions extending from both ends of the semi-circular arc portion and crossing each other. One of the straight portions of the support portion is short, and when the sock is worn on the foot, its free end is located near the base of the fourth toe on the sole side. The other straight portion is long, and when the sock is worn on the foot, its free end reaches the side of the base of the thumb. The expansion and contraction rate of the support portion is lower than that of the body portion other than the support portion. The opening edge portion and the body portion are knitted while rotating the cylinder of the circular sock knitting machine in one direction. A method for manufacturing a sock, characterized by the above.

2. A reinforcing portion is arranged in the portion surrounded by the semi-circular arc portion and the two straight portions extending from both ends of the semi-circular arc portion and crossing each other. The method for manufacturing a sock according to claim 1, characterized by the above.

3. The body portion has an increasing pressure on the foot gradually from the semi-circular arc portion toward the toe side. The method for manufacturing a sock according to claim 1 or 2, characterized by the above.

4. The support portion is formed by a cut boss method. The method for manufacturing a sock according to any one of claims 1 to 3, characterized by the above.

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